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EP3944932A1 - Verfahren und montageeinheit zur durchführung von montageoperationen - Google Patents

Verfahren und montageeinheit zur durchführung von montageoperationen Download PDF

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Publication number
EP3944932A1
EP3944932A1 EP20382678.9A EP20382678A EP3944932A1 EP 3944932 A1 EP3944932 A1 EP 3944932A1 EP 20382678 A EP20382678 A EP 20382678A EP 3944932 A1 EP3944932 A1 EP 3944932A1
Authority
EP
European Patent Office
Prior art keywords
target
end effector
robot
vehicle body
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP20382678.9A
Other languages
English (en)
French (fr)
Other versions
EP3944932B1 (de
Inventor
Jesús FREIRE
Jorge Vidal Ribas
Sergi Rodriguez Muñio
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Schweiz AG
Original Assignee
ABB Schweiz AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Schweiz AG filed Critical ABB Schweiz AG
Priority to EP20382678.9A priority Critical patent/EP3944932B1/de
Priority to CN202110830935.2A priority patent/CN113978576A/zh
Priority to US17/384,452 priority patent/US20220024041A1/en
Publication of EP3944932A1 publication Critical patent/EP3944932A1/de
Application granted granted Critical
Publication of EP3944932B1 publication Critical patent/EP3944932B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/024—Positioning of sub-units or components with respect to body shell or other sub-units or components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
    • B25J9/1697—Vision controlled systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
    • B25J13/081—Touching devices, e.g. pressure-sensitive
    • B25J13/082—Grasping-force detectors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
    • B25J13/088—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices with position, velocity or acceleration sensors
    • B25J13/089—Determining the position of the robot with reference to its environment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1628—Programme controls characterised by the control loop
    • B25J9/1633—Programme controls characterised by the control loop compliant, force, torque control, e.g. combined with position control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B25J9/1684—Tracking a line or surface by means of sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B25J9/1687—Assembly, peg and hole, palletising, straight line, weaving pattern movement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/024—Positioning of sub-units or components with respect to body shell or other sub-units or components
    • B62D65/028—Positioning of sub-units or components with respect to body shell or other sub-units or components by determining relative positions by measurement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/06—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components the sub-units or components being doors, windows, openable roofs, lids, bonnets, or weather strips or seals therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/14—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components the sub-units or components being passenger compartment fittings, e.g. seats, linings, trim, instrument panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/18—Transportation, conveyor or haulage systems specially adapted for motor vehicle or trailer assembly lines
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/36—Nc in input of data, input key till input tape
    • G05B2219/36048—Verify, probe workpiece, if position deviation edit, modify program

Definitions

  • the present disclosure is related to a method and to an assembly unit for performing an assembling operation on a part having a target for the assembling operation. Also disclosed is an assembly line, for example an automotive final assembly line, with such an assembly unit.
  • Automotive production lines for manufacturing vehicle bodies usually include a final assembly line where human operators and/or robots may operate to assemble components such as seats, doors, windshield, wheels, steering mechanisms, etc. on vehicle bodies that are advanced along the assembly line by suitable transport means such as chain conveyors, overhead conveyors, AGVs (Automated Guided Vehicles), etc.
  • suitable transport means such as chain conveyors, overhead conveyors, AGVs (Automated Guided Vehicles), etc.
  • An assembly robot for such an assembly line may typically be an industrial robot, provided with an end effector that carries a tool for performing an operation and/or carries a component (e.g. a wheel, a door, etc.) for attaching the component to the vehicle body.
  • the end effector of the robot is controlled to perform a certain operation on a target of the vehicle body, for example attaching a door to the vehicle body by inserting the hinge pins of the door in corresponding hinge bushings of the vehicle body.
  • each vehicle body may be in a slightly different position on a conveyor or AGV, such that the door hinge bushings or other target for an assembly operation may not always be in the same position. Variations in the expected positioning of a target may be even more challenging when one of the elements to be assembled is moving, e.g. on a conveyor or AGV, during the assembly operation.
  • force control allows the end effector of the robot to adapt to the particular position of the elements to be assembled by reacting to the physical contact between the component to be assembled (carried by the end effector of the robot) and the target on the vehicle body.
  • the controller controls the robot to complete the assembly operation depending on the forces that are exerted on the end effector due to said physical contact and are sensed by the force sensor.
  • a method according to claim 1 for example, a method for handling components that are to be assembled on a target, the target belonging to a part, such as a vehicle body.
  • the method comprises:
  • This determination and registration of the target position is carried out for each individual part, e.g. each individual vehicle body of a batch of vehicle bodies advancing in an assembly line, before the assembly operation is performed on the individual part.
  • a location utensil attached to the industrial robot that performs the assembly allows the target position for each particular part to be accurately determined, registered, and used for the assembly operation, thus overcoming the difficulties associated with irregular or imprecise placement of the parts, poor repeatability, etc. and providing precise and safe assembly operations.
  • the component to be assembled e.g. a vehicle door
  • the part on which the assembly is performed are exposed to scratches and other damage that may be caused from unwanted contact of the component itself with the target, as may happen in a conventional assembly operation that is guided by force control, especially in certain operations where there is little space to manoeuvre.
  • a dedicated location utensil may allow a fast, safe and accurate determination of the position of the target, because, unlike the component to be assembled, the location utensil may be designed with any shape or configuration that is convenient for facilitating the approach to the target and the contact with it, and for providing a very stable contact with targets of any shape, dimension and orientation.
  • a dedicated utensil may also be designed with surfaces that reduce the risk of damage to the target and provide a smooth contact with the target, e.g. with a coating of polytetrafluoroethylene (PTFE), elastomers or the like.
  • PTFE polytetrafluoroethylene
  • force control may be more robust in certain conditions, and be less affected for example by poor light conditions, colour of the target, etc.
  • the robot controller may register the absolute position of the location utensil, e.g. taking as reference the robot base, when the utensil is in the predetermined relative position with respect to the target, and this absolute position is indicative of the position of the target, which may therefore be determined by the robot controller. In some cases determining the position of the target may require applying constant correction values to the absolute position of the location utensil, depending on the geometry of the target and location utensil.
  • the position of the target is defined herein as the absolute position of the target, e.g. taking as reference the stationary robot base.
  • the predetermined position of the location utensil relative to the target, and in contact with the target, may be detected by the controller depending on the forces acting on the end effector and sensed by the force sensor: a predetermined set of forces acting on the end effector (i.e. a predetermined set of readings of the force sensor) may be associated with the predetermined position of the location utensil relative to the target.
  • the location utensil may be shaped to contact the target on three perpendicular planes (e.g. it may comprise three plates forming 90° angles): when the forces acting on the end effector in the three perpendicular directions reach a predetermined threshold, this indicates stable contact between the location utensil and the target.
  • Other shapes and configurations of the location utensil may be implemented, depending on the target.
  • the predetermined set of readings of the force sensor corresponding to the predetermined position of the location utensil relative to the target may comprise forces in at least in one direction, for example in three perpendicular directions, and may also comprise torques about at least one axis, for example about three perpendicular axes.
  • a force sensor to detect external forces acting on the end effector may be mounted on the robot between the wrist and the end effector, to detect the strain between the two elements and provide information about the forces and torques acting on the end effector, and therefore about the relative position between the end effector and the location utensil.
  • Force and/or torque sensors may also be associated to several robot axes. The output of the sensors is connected to the controller, such that the controller may control and guide the movement of the end effector depending on the readings of the sensors, i.e. with force control.
  • Such force/torque sensors may be provided with resistance strain gauges to measure the strain applied in several degrees of freedom, for example in all six degrees of freedom (three force components and three torque components).
  • an indirect force sensor may be provided, to determine the current consumed by the actuators of the robot, e.g. the internal motors for moving each robot axis: the consumed current of a motor and the torque on the motor are proportional, and the torque on the motor is a function of the robot dynamics and of external forces acting on the robot, so sensing or measuring the consumed current allows determining the external forces.
  • the end effector of the industrial robot is controlled to approach the target based on the readings of a vision system, which may comprise a vision sensor mounted on the end effector.
  • determining the target position comprises controlling the end effector of the robot to reach the predetermined position of the location utensil relative to the target by a combination of the readings of the vision system (i.e. by a visual servoing process) and force control based on the readings of the force sensor (also referred to as compliant behaviour or soft control).
  • control of the end effector for positioning of the location utensil relative to the target may be performed as described in detail for an assembly operation in WO2019/154858 , page 18, line 1 to page 26, line 22, and corresponding Figures 3 and 4 .
  • the absolute position of the location utensil when it is in the predetermined position relative to the target may be indicative also of the target orientation, such that once this predetermined position has been reached, both the target position and the target orientation may be registered, and the end effector of the robot may be controlled to perform the assembly operation at the registered target position and according to the registered target orientation.
  • the target may comprise two spaced apart features, such as two aligned hinge bushings
  • the component to be assembled may comprise features matching the target features, such as two aligned hinge pins.
  • the orientation of the two hinge bushings is also indicated by the absolute position of the location utensil when it is in the predetermined position relative to the target. The detection of this position may involve e.g. detecting forces and torques acting on the end effector: for example, a torque may indicate that the location utensil is in contact with only one of the two features of the target.
  • the assembly operation may then comprise controlling the end effector to position the component such that the features (e.g. two hinge pins) that match the target features (e.g. two hinge bushings) are in the same orientation as the registered orientation of the target features.
  • the features e.g. two hinge pins
  • the target features e.g. two hinge bushings
  • the part having the target on which an assembly operation is to be performed is moving during the determination of the target position and during the assembly operation, and the method further comprises:
  • the controller of the end effector may start updating the registered target position with the part tracking data, e.g. in real time, so the subsequent assembly operation may be performed according to the updated target position.
  • the robot may be displaceable, e.g. the robot base may be mounted on a track and controlled to travel synchronized with the part tracking data during the determination of the target position and the assembly operation, such that the target position with respect to the end effector is substantially constant and the assembly operation is performed as if the target was substantially stationary with respect to the robot.
  • the assembly operation may comprise dropping or mounting a component that is carried by the end effector on the target: for example, the target may be a hinge bushing of the part, and the assembly operation may comprise mounting a component on the part by dropping a hinge pin of the component in the hinge bushing.
  • the end effector carries the component to be assembled on the target already during the step of determining the target position, i.e. the component is picked by the end effector, e.g. a gripper of the end effector, before the target position is determined, such that the component may be assembled shortly after the target position is registered.
  • the end effector may be controlled to pick the component to be assembled on the target only after the step of determining the target position is completed.
  • One or the other of the two alternative solutions may be preferable depending on the circumstances, e.g. on the configuration of the component, the time available for the operation, the required accuracy, etc.
  • the part with the target may be a vehicle body mounted on a transport system and advanced in an automotive final assembly line, and the industrial robot may be arranged along the assembly line to pick, drop or mount a vehicle component on the vehicle body, at the desired target.
  • Vehicle components which could be mounted on the vehicle body with embodiments of the method may be doors, wheels, the dashboard, and many others.
  • methods according to embodiments of the present disclosure may be for performing an assembly operation with an industrial robot, in which a component is assembled on a target of a part; including but not limited to assembly lines for electrical appliances or other products, individual assembly operations, etc., All features and details disclosed herein in relation with the assembly of a component on a vehicle body are similarly applicable to the assembly of a component on a target of any other object.
  • the position and/or orientation with respect to the industrial robot of the component is also determined and registered prior to the assembly operation, so as to facilitate and make more accurate the operation itself, by accurately matching the position and orientation of the component with those of the target on the part.
  • This determination of the position and/or orientation of the component with respect to the industrial robot may be performed with the help of an auxiliary location utensil, by operating in a similar way as in the determination of the target position in the above methods.
  • the end effector of the industrial robot carrying the component may be controlled, e.g. with the help of a vision system, so that the component approaches the auxiliary location utensil; once there is contact between the auxiliary location utensil and the component, the end effector of the robot may be controlled at least through force control, based on the readings of the force sensor, and optionally also through the vision system, to reach a predetermined position of the component with respect to the auxiliary location utensil. At this point, the position and orientation of the component, e.g. with reference to the robot base, may be registered to be used in the subsequent assembly operation.
  • the auxiliary location utensil is external to the robot carrying the component, and it may be stationary and passive, e.g. mounted on a dedicated fixture within reach of the industrial robot carrying the component, or it may be carried by an auxiliary robot.
  • one of the operations of assembling the door e.g. the assembly of the door on the door holding fixture, may be carried out in a conventional way, without the determination of the target position using a location utensil.
  • the vehicle body may be on the move in the production line during the reassembly operation of the door on the vehicle body hinges.
  • the door holding fixture or support may be provided with fixture hinges to receive the door, similar to the hinges of the vehicle body, and it may be attached to a transporter so as to travel, e.g. substantially in parallel with the vehicle body from the first station of the assembly line to the second station of the assembly line, while it is fitted with sub-components such as windows, trim, seals, loudspeakers, etc.
  • the present disclosure provides an assembly unit for assembling a component on a target of a part in an assembly line, the assembly unit comprising:
  • the force sensor may be mounted on the robot between the wrist and the end effector to provide data about external forces and torques acting on the end effector, and therefore about the relative position between the end effector and the location utensil.
  • the assembly unit further comprises a vision system with a tracking vision sensor for tracking the movement of the part along the assembly line, and the controller in further configured for controlling the end effector of the robot to perform the assembly operation at the target position based on the registered target position and based on the tracking of the movement of the part.
  • an automotive final assembly line comprising a transport system to advance a part, such as a vehicle body, along the assembly line, and an assembly unit as disclosed in any of the above examples, arranged to perform an assembly operation in target area of the part or vehicle body, according to embodiments of the method disclosed herein.
  • Figure 1 shows schematically, and not at scale, an assembly line 110, in the example an automotive final assembly line, where a transporting system 130 advances a part, in the example a vehicle body 120, in an advance direction, past an assembly unit 150.
  • the assembly unit 150 comprises an industrial robot 160, which may comprise a controller and a number of programmable axes, i.e. rotational and/or linear degrees of freedom, between a robot base and a robot wrist, each axis having an associated driving element, such as a motor, controlled by the robot controller.
  • an industrial robot 160 which may comprise a controller and a number of programmable axes, i.e. rotational and/or linear degrees of freedom, between a robot base and a robot wrist, each axis having an associated driving element, such as a motor, controlled by the robot controller.
  • the configuration of an industrial robot is known, and the details are not shown in the figures.
  • the robot 160 may be provided with an end effector 161 attached to the robot wrist, to perform a certain operation, for example a gripper, a tool a support for holding a part to be assembled, etc.
  • the robot base may be attached to the floor, or it may be roof or wall mounted, or it may be mounted on a track e.g. parallel to the assembly line.
  • the vehicle body 120 may be transported at a constant speed of about 100 mm/s, for example on a skillet or overhead conveyor or on an AGV (Automated Guided Vehicle).
  • AGV Automatic Guided Vehicle
  • the vehicle body 120 may comprise a target 121 (indicated with a circle) for the assembly operation.
  • the target 121 of the vehicle body 120 may be e.g. a recess, a hole, a pin, combinations of several holes and/or pins, etc., where matching features of another part, such as a door or a wheel, must be fitted during the assembly operation.
  • An assembly operation may comprise e.g. dropping, attaching or otherwise assembling a component on the target.
  • Examples of operations which may be performed with an industrial robot provided with a suitable end effector, according to embodiments of the method and assembly unit disclosed herein, may be disassembling the doors from the vehicle body, before other internal elements are inserted, and dropping the doors on targets of dedicated supports or fixtures; re-assembling the doors on targets of the vehicle body; assembling the vehicle dashboard or the wheels on targets of the vehicle body, etc.
  • Vehicle doors may be removed from the vehicle body at a first station along the assembly line, such as to that there is free access to inner areas of the vehicle body, e.g. to mount the dashboard, and later re-assembled at a second downstream station of the assembly line.
  • Figure 1 may schematically represent one of such stations of the assembly line, e.g. the first station, where a door (not shown in Figure 1 ) is removed from the vehicle body 120, or e.g. a second station, where the door is re-assembled on the vehicle body 120, at vehicle body target 121 (schematically indicated with a circle in the figure and which in this case may comprise two hinge bushings).
  • the door When removed from the vehicle body 120, the door may be placed on a dedicated support, i.e. a door holding fixture 220, which may also be mounted on a transporter 230, for example an AGV (Automated Guided Vehicle) for being displaced towards the second station, as shown by arrow D2.
  • the door holding fixture 220 may have a target 221 (indicated with a circle) for an assembly operation, i.e. for receiving the door: for example, the fixture target 221 may comprise two hinge bushings in which complementary hinge pins of the door are inserted in the assembly operation.
  • the door may be fitted with moldings, windows, door trim and other elements, while it is displaced from one station to another while placed on the door holding fixture 220, before being re-assembled to the vehicle body 120.
  • Figure 2 shows schematically an example of the assembly unit 150, comprising the industrial robot 160 fitted with the end effector 161 attached to the robot wrist, and a controller 151, which may be the controller of the robot 160.
  • the end effector 161 may have attached a location utensil 162, and a gripper 163 to pick and release a component, such as a door, to be assembled.
  • a force sensor 164 may be arranged between the wrist of the robot 160 and the end effector 161 to sense external forces acting on the end effector 161.
  • the assembly unit 150 may also comprise a vision system, with a vision sensor 165, such as a camera.
  • the vision system may provide readings to the controller 151, to control the movement of the end effector 161 during at least part of an assembly operation.
  • the camera or other vision sensor 165 may be mounted attached to the end effector itself, as shown schematically in Figure 2 .
  • the assembly unit 150 may also comprise an additional vision system, e.g. stationary vision sensor 152 to track the advance of the vehicle bodies along the assembly line 110.
  • Embodiments of such a vision system may be as described in US2011/0087360 or in WO2019/154858 and may operate in the same manner.
  • the controller 151 may be configured to determine and register the position of the target 121 or 221 of the part, e.g. the vehicle body 120 or the door holding fixture 220, and to control the end effector 161 to perform the assembly operation at the registered target position.
  • the controller 151 may perform the following steps:
  • the absolute position of the target can be accurately determined, because the absolute position of the location utensil is known to the controller, and so is the relative position between them.
  • absolute position of an object it is meant the spatial position of the object taking as reference the stationary robot base, i.e. in a coordinate system fixed to the robot base; or fixed to the floor, if the robot is mounted on a track.
  • the absolute position of the target will be generally referred to as "the position of the target”.
  • Figures 3a and 3b are side views taken from different angles, showing the end effector 161 of the robot 160 with a location utensil 162 attached thereto (only the wrist of the robot 160 is depicted in the figure).
  • the end effector 161 is carrying a vehicle door, held by a gripper 163 (the gripper including e.g. suction cups attached to the window).
  • the vehicle door has two hinge pins 322, 323 ( Figure 3a ) intended to be inserted in two corresponding hinge bushings, when the door is assembled on the vehicle door 120 and also when it is dropped on the door holding fixture 220.
  • the location utensil 162 is elongate and constructed with three plates arranged perpendicular to each other (as more clearly visible in Figures 4a-4c ), which allows determining the position and orientation of the two hinge bushings of the target simultaneously and accurately, as is described in the following.
  • Figures 4a-4c show in perspective view the location utensil 162 attached to the end effector 161, in three successive positions during the process in which the controller 151 guides the end effector 161 such that the location utensil 162 approaches the target 221 of the door holding fixture 220 and reaches a predetermined position relative to the target 221.
  • the target 221 comprises two features, i.e. two hinge bushings 222, 223 on a hinge axis 224, in which the two hinge pins 322, 323 of the vehicle door are to be received.
  • the end effector is being guided by the controller 151 e.g. by visual servoing, to approach the target 221 as shown by the arrows, with a general orientation that is similar to that of the hinge axis 224 of the target 220, which may be determined by the controller from the vision sensor readings, or may be preprogrammed.
  • the controller starts guiding the location utensil also by force control: the robot becomes "soft", i.e. not stiff, such that it is allowed to deviate to a certain extent from an intended trajectory depending on the applied external force, e.g. depending on the components of force and torque detected by the force sensor 164.
  • the controller 151 first guides the location utensil 162 towards the hinge bushings 222, 223 until they are both in the inner corner of the utensil 162, i.e. until each hinge bushing 222, 223 is in contact with both elongate plates of the utensil 162. A this point the location utensil 162 is oriented in the direction of the hinge axis 224, and it matches the position of the hinge bushings 222, 223 in the two directions perpendicular to the hinge axis 224. This position of the location utensil 162 is shown in Figure 3b .
  • the controller then displaces the location utensil 162 upwards along the hinge axis 224 (as shown by the arrow in Figure 3c ) until the hinge bushing 223 contacts the lower plate of the location utensil 162, this contact being sensed by the force sensor 164.
  • the predetermined relative position is determined by the controller from the readings of the force sensor 164.
  • the controller 151 may then accurately determine and register the target 221 position and orientation (i.e. the absolute position and orientation of the target 221, referenced e.g. to the robot base), which are univocally established by the absolute position and orientation of the location utensil 162.
  • the target 221 position and orientation i.e. the absolute position and orientation of the target 221, referenced e.g. to the robot base
  • the controller 151 then operates the end effector 161 to withdraw the location utensil 162 from the target 221; to move the vehicle door with the hinge pins 322, 323 towards the target 221; to perform the assembly operation by inserting the hinge pins 322, 323 of the door in the hinge bushings 222, 223 of the door holding fixture 220, using the registered position and orientation of the target; and to release the door, leaving it hanging on the door holding fixture 220.
  • the controller 151 may determine and register the precise position and/or orientation of the vehicle door hinges 322, 323 with respect to the end effector 161.
  • Such an auxiliary location utensil 402 may be stationary and passive, i.e. to simply serve as a fixed reference.
  • the controller 151 may control the end effector 161 carrying the door to approach the auxiliary location utensil 402, then use force control, based on the readings of the force sensor 164, to reach a predetermined position of the door hinges 322, 323 with respect to the auxiliary location utensil 402.
  • the position and orientation of the door hinges 322, 323, e.g. with reference to the robot base may be registered by the controller 151, to be used in the subsequent assembly operation.
  • An assembly unit 150 and an assembly process analogous to those described above for dropping the vehicle door on a door holding fixture 220, may be employed for the subsequent operation of re-assembling the door on the vehicle body 120.
  • the location utensil 162 may be employed in the same manner to determine and register the position and orientation of the target 121 on the vehicle body 120 ( Figure 1 ), the target 121 comprising two hinge bushings (not shown) similar to hinge bushings 222, 223.
  • the part with the target on which a component must be assembled may be moving, e.g. in the case of a vehicle body in a final assembly line.
  • An example of such a case is for example the re-assembly of the door on the target 121 (hinge bushings) of the vehicle body 120 described in the previous paragraph.
  • the part with the target my move with constant or variable speed, and possibly including stops.
  • the target may be moving during the process described above for determining the target position and/or during the assembly operation.
  • the assembly unit 150 may then track the movement of the part, e.g. vehicle body 120, along the assembly line.
  • the assembly unit 150 may comprise a vision system, including one or more tracking vision sensors 152 (see Figure 1 ) such as cameras, arranged stationary along the assembly line or mounted on a robot, for tracking the movement of the part in the assembly line.
  • the tracking vision sensors 152 may track a feature of the part itself (e.g. a hole in the vehicle body), or it may track a marking, which may be attached to the part itself or to the transporter advancing the part, such as an AGV, a skid, a skillet, etc.
  • the controller 151 may then control the end effector 161 of the robot 160 during the assembly operation based on the registered target position and also based on the movement of the part as tracked by the vision sensors 152, from the moment the position of the target is registered and until the assembly operation is completed. For example, as soon as the target position is determined and registered the controller 151 may start updating the registered target position with the tracking data according to the readings of the tracking vision sensor 152, e.g. in real time, so the subsequent assembly operation is performed according to the updated target position.
  • the tracking vision sensor 152 may optionally be used also during the determination of the target position: in this process the controller 151 may control the end effector 161 of the robot 160 based not only on the robot vision system and force control, but also based on the readings of the tracking vision sensors 152.
  • the robot 160 may be displaceable, e.g. the robot base may be mounted on a track (not shown) and controlled to travel synchronized with the part according to the readings of the tracking vision sensor 152, during the determination of the target position and during the assembly operation, such that the relative position of the target with respect to the end effector is substantially constant.
  • Figure 5 is a flow diagram of a method 500 according to the present disclosure for handling components that are to be assembled on a part, the part having a target for the assembly operation, as for example the method explained above for dropping the vehicle door on the door holding fixture 220.
  • the industrial robot is provided with an end effector and a location utensil attached to the end effector, a force sensor arranged to detect external forces on the end effector, e.g. between the wrist of the robot and the end effector, and a vision sensor.
  • the position of the target is determined, through the steps of: controlling in block 530 the end effector of the robot to approach the target, by a visual servoing process based on the readings of the vision sensor; detecting in block 540 when the location utensil contacts the target, based on the readings of the force sensor; controlling in block 550 the movement of the end effector of the robot at least by force control, based on the readings of the force sensor, to reach a predetermined position of the location utensil relative to the target, and determining in block 560 the target position as indicated by the absolute position of the location utensil when the location utensil is in the predetermined position relative to the target;
  • the target position determined in block 560 is registered by the robot controller.
  • the end effector may pick a component to be used in the assembly operation before the step of block 530, or it may pick the component only after the position of the target is registered in block 570.
  • the position and/or orientation of a component to be assembled may be determined in a similar way as in the determination of the target position of blocks 630-570, but with the assistance of an auxiliary location utensil, e.g. external to the robot and stationary, such as described above.
  • Figure 6 is a flow chart illustrating a method for assembling components on a vehicle body 120, and more particularly a method for handling the doors of the vehicle in an automotive final assembly line, which may comprise using embodiments of the method 500 according to the present disclosure in two different stations of the assembly line 110 (see Figure 1 ).
  • This method illustrated in Figure 6 first comprises, in block 610, removing the door from the vehicle body 120 at a first station, by lifting it from the hinge bushings with a first industrial robot, such as robot 160 shown in Figure 2 .
  • the method 500 of Figure 5 is performed to place the door on a door holding fixture 220 with target 221 comprising hinge bushings 222, 223 such as described in relation to Figures 4a-4c : in this case, the part having the target is the holding fixture 220.
  • the door may be again re-assembled on the vehicle body 120: for this purpose, in block 630 the vehicle door is removed from the holding fixture 220 in a second station, downstream of the first station along the assembly line 110, using a second industrial robot, like robot 160 shown in Figure 2 ; the holding fixture 220 with the door mounted on it has travelled to the second station on the transporter 230 (see Figure 1 ).
  • the method 500 of Figure 500 is again performed, this time to reassemble the door removed from the holding fixture 220 on the vehicle body 120.
  • the part having the target is the vehicle body 120
  • the target 121 (only schematically indicated on Figure 1 ) comprises the vehicle body hinge bushings (not shown in detail in the figures), in which the hinge pins 322, 323 of the door (see Figure 3a ) are inserted during the assembly operation.
  • one industrial robot or several industrial robots may be employed, either working independently from each other or working jointly, for example gripping and/or assembling a part between them, delivering a part from one robot to another, etc.
  • they may each have an associated vision system, or several of them may be controlled using data from the same vision system.
  • an "industrial robot” is an automatically controlled, reprogrammable multipurpose manipulator that is programmable in three or more axes, in accordance with the definition of ISO Standard 8373.
  • the robot axes are each provided with an actuator, for example a motor, and each individually programmable and controlled. They may be arranged, for example in series, between a robot base which is attached to the floor, roof mounted, etc., and a robot wrist to which end effectors may be fitted.
  • Examples of commercial industrial robots that may be employed in an assembly line such as disclosed herein may be models IRB 4600, IRB 6700, IRB 7600, etc., all available from ABB, Zurich, Switzerland ( www.abb.com ).
  • the robot base of industrial robots employed in embodiments disclosed herein may be directly attached to the floor, or it may be mounted on a supporting structure, roof mounted, mounted on a moving track, etc.
  • the movement of the track may be controlled by the robot controller and may be considered conceptually as an additional programmable degree of freedom or axis of the robot itself.
  • Different end effectors to be operated by the industrial robot may be mounted on the wrist of the robot: for example, grippers for handling an assembly component to be mounted on a part such as a vehicle body in an assembly line, tools such as a welding tool, etc.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Manufacturing & Machinery (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Chemical & Material Sciences (AREA)
  • Human Computer Interaction (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Automatic Assembly (AREA)
  • Manipulator (AREA)
EP20382678.9A 2020-07-27 2020-07-27 Verfahren und montageeinheit zur durchführung von montageoperationen Active EP3944932B1 (de)

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EP20382678.9A EP3944932B1 (de) 2020-07-27 2020-07-27 Verfahren und montageeinheit zur durchführung von montageoperationen
CN202110830935.2A CN113978576A (zh) 2020-07-27 2021-07-22 用于执行组装操作的方法和组装单元
US17/384,452 US20220024041A1 (en) 2020-07-27 2021-07-23 Method and an assembly unit for performing assembling operations

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TWI764377B (zh) * 2020-11-16 2022-05-11 達明機器人股份有限公司 機器人安全補償重量的系統及方法
CN115416741B (zh) * 2022-10-12 2024-05-10 Abb瑞士股份有限公司 用于推车式电气设备的防倾倒装置和推车式电气设备
CN115674080B (zh) * 2022-11-02 2024-09-06 一汽解放汽车有限公司 车窗装配系统

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US20110087360A1 (en) 2008-03-31 2011-04-14 Abb Research Ltd. Robot parts assembly on a workpiece moving on an assembly line
EP3520971A1 (de) * 2018-02-06 2019-08-07 ABB Schweiz AG Zusammenbauen von teilen in einer montagelinie
WO2019154858A1 (en) 2018-02-06 2019-08-15 Abb Schweiz Ag Assembling parts in an assembly line

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